Brush construction



March 9, 1965 J. F. ARENA 3,172,141

BRUSH CONSTRUCTION Filed March 2B. 1960 F/az BY i arme/vn United StatesPatent O 3,172,141 BRUSH CNSTRUCTEGN .lohn F. Arena, Franklin Square,NY., assigner to Baker rush Co., Enc., New York, N .Y., a corporation ofNew or r Filed Mar. 28, 196i), Ser. No. 1S,l36 Claims. (Cl. 1S-192) Thisinvention relates to a brush construction, more particularly to animprovement in a paint brush construction.

Still more particularly, this invention relates to a brush constructionhaving particular utility in the'rnanufacture of paint brushes, andproviding substantial economies in manufacture, simplification ofassembly procedures, and at the same time an improved end product.

Still more particularly, this invention relates to an improved brushassembly permitting the economical use of materials heretoforeconsidered to be impractical for use in brush and handle constructions.

Still more particularly, this invention relates to a brush constructionhaving a reduced number of component parts which may be assembledwithout the necessity of nailing the component parts together, and whichnonetheless possessesrequal or greater structural rigidity andpermanence as compared to brushes utilizing nails, screws, or likemechanical fastening elements.

Still more particularly, this invention relates to a brush constructionand method of assembly wherein the component parts are secured togetherentirely by a cementitious compound applied in the course of setting thebristles in a ferrule.

In conventional brush structures, the root or butt end of the bundle ofbristles is inserted part way into a bristle containing ferrule. Abristle setting compound, normally a vulcanizable material, isintroduced into the ferrule in contact with the root ends of thebristles and is subsequently vulcanized. To overcome losses by shrinkageof cement from the ferrule, after vulcanization brads or like materialfastener elements are driven through the ferrule into the knotcomprising the butts of the bristles and the setting compound, causingthe knot to be secured within the ferrule, and assembly of the brush iscompleted by insertion of a handle, `normally of wood, into the otherend of the ferrule, the said handle being secured to the ferrule againby brads or the like, driven through the ferrule and into the handle.

More recently it has been proposed that the former described nailingstep be eliminated from the brush manufacturing procedure by theprovision of an anchoring spacer member which may be vulcanized withinthe mass of bristle setting compound in contact with the butt ends ofthe bristles, in which case the only nailing step recommended is thatwhich connects the ferrule and anchoring spacer block to the handle bymeans of brads which are driven through the ferrule and anchoring spacerand into the handle.

Both of the previously described construction methods and structurespresent the drawbacks inherent in the use of mechanical fastenersincluding the possibilities of splitting of the setting compound in theferrule, the exposure in the iinished brush of protruding nail heads orthe'like, the necessity that the handle portion be of a thickness andmaterial capable of accepting the nails or brads utilized, and theincrease in labor costs involved in the nailing step.

Accordingly, it is an object of this invention to provide a brushstructure which completely eliminates the use of nails or likemechanical fastening elements.

A further object of this invention is to provide a novel brushconstruction in which a low cost, light weight hollow handle member maybe used, which handle member ice characteristics as compared with thestructure utilizing the mechanical features.

Still a further object of this invention is the provision of a brushconstruction having an integral handle which may be made of relativelythin walled, exible plastic material not heretofore considered to beacceptable for use Iin such application, in the degrees of thickness andilexibility made practicable through the novel construction hereindescribed and claimed.

Still a further object of this invention is to provide a novel method ofmanufacturing a brush.

Other objects of this invention will be understood when considered inconjunction with the accompanying drawings, in which:

FIGURE 1 is a vertical cross section through a completed paint brush inaccordance with the invention;

FIGURE 2 is a View taken on the line 2-2 of FIG- URE l;

FIGURE 3 is a perspective view of the bristle and ferrule sub-assemblyprior to attachment to the handle;

FIGURE 4 is a perspective View of a handle sub-assembly preparatory tobeing joined to the sub-assembly shown in FIGURE `3.

As shown in FlGURE 3, a tubular ferrule 10, of metal or lthe like, isiilled or stuifed at its lower end 11 with the root or butt ends 12 ofbristles 13. A plug or spacer 14 of wood or the like may be provided incontact with the butt ends 12 of the bristles 13, to give added body tosaid bristles, while at the same time aiding in maintaining saidbristles in the end 11 of ferrule 10. A measured quantity of liquidbristle setting compound is then introduced through the end 15 of theferrule 10 into contact with the butt ends 12 of the bristles 13, andplug or spreader 14. The setting compound 16 is preferably a coldcuring, selfsetting composition having little or no tendency to shrinkas curing progresses.

A good example of a form of setting compound may include epoxy,polyhydroxy, polyether resins, or esters thereof, as disclosed in UnitedStates Patent No. 2,569,- 920, but other setting compounds known to theart may be used. Such so-called epoxy resin cements have the desirableproperties aforesaid of self-curing without the requirement of heatingthe mass, and little or no shrinkage upon curing, and have the furtheradvantage of being available in a variety of viscosities to vary thedegree of penetration into the butt ends of the bristle members by thecompound, thereby permitting a matching of the viscosity of the settingcompound to vthe bristle materials employed, in a manner well known tothose skilled in the art, to permit optimum holding power for the massof bristles secured within the ferrule.

As seen in FIGURES l and 2, the liquid setting compound lls the ferrulesubstantially to a point about half way between the top edge 15 of theferrule and the upermost portion 17 of the bristles 13.

With the ferrule partially filled with liquid bristle setting compoundas previously set forth, assembly of the brush is completed by insertioninto the ferrule of the lower or shank portion of thehandle sub-assembly20. The handle 2t), in its preferred form, is made of polyethyleneplastic material. While the thickness of the walls dening the grippingportion 21 must be such as to present a fairly rigid structural member,however, as will be understood more fully from the ensuing description,the slight tendency of the gripping portion 21 to collapse under manualpressure prior to completion of 3. the assembly of the brush, is notnecessarily an indication that the walls of the portion 21 are not thickenough, since assembly of the handle with the ferrule member producesgreater rigidity in said handle portion than was the case in theunassembled condition of the handle.

The handle 20, adjacent the lower portion of the gripping portion 21, isprovided with` a peripherally extending stop bead or ferrule abuttingshoulder 22. Below the bead 22 the handle desirably includesconvergently tapering side walls or skirts 23, 24, and generally arcuateend walls 25, 26, all together providing a ferrule fitting shank. Theend walls 25, 26, like the side walls 23, 24, preferably converge ortaper inwardly from their widest point adjacent the bead or rim 22providing camming means. Moreover, walls 25, 26 may extend a distancebeyond the lowermost portions 27, 28, of side walls 23, 24,respectively. The lower portions 29, 30 of the end walls 25, 26,respectively, are provided with transverse apertures 31, 32,respectively, for purposes which will appear.

The portions of walls 23, 24, 25, 26, adjacent the bead 22, arepreferably slightly oversized with respect of the dimensions of theperiphery of the ferrule 10 and its upper end 15. Thus, when the shankportion of the handle 20 is inserted in the upper end- 15 of ferrule 10,bead 22 is retained abutting against said upper end 15 by the frictionalengagement of the resilient plastic walls of the shank of the handle 20and the inner periphery of the ferrule 10.

Moreover, the tight fit, particularly of the side walls 25, 26, againstthe corresponding inner peripheral points at the upper edge of theferrule 10, will cause a slight inward flexing or deformation of thewalls 25, 26, for purposes which will appear hereafter.

When the lower portions of the handle are inserted into the ferrule 10so that the bead 22 engages or abutts the upper end 15 of said ferrule,the lower edges 27, 28, of the walls 23, 24, will preferably be immersedor dipped slightly below the level of the bristle setting compound 16,and the lower portions 34, 35, of the longer side walls 26, 25,respectively, will be in close adjacency to, but not touching, the upperedge 17 of the butt ends 12 of the bristles 13.

As previously indicated, the intimate or slightly oversized fit of thelower portion of the shank of the handle assembly 20 with the innerperiphery of the upper portion 15 of ferrule 10, preferably causes aninward, lateral displacement of the end portions 29, of the skirt of endwalls 25, 26. Where such lateral movement of the end portions 29, 30 ispresent, there is little or no likelihood that air might becomeentrapped within the apertures 31, 32, and thus a ow of bristle settingcomposition through apertures 31, 32, and complete displacement of airentrapped in said apertures is virtually assured by the inward flexingaction previously described.

Moreover, a slight additional flexing and unilexing of the portions ofhandle 20 not immersed in the compound will augment the flow of compoundthrough the apertures and into the hollow mouth portion.

When the compound 16 has set and hardened by the means prescribed forthe cement, the handle assembly 20 will be firmly and permanentlysecured within the ferrule. The permanence of such bonding is augmentedby the constricted mouth presented by the inwardly tapering, convergingwalls 23, 24, 25, 26, since such constricted construction assures thatthe shank of the handle is retained within the ferrule by more thanmerely the bonding between the setting compound and the immersedportions of the handle, since hardened setting compound between thehandle and said ferrule prevents outward flexing of said Walls andhardened compound within the handle prevents inward flexion. Thus, thebond between the handle and the ferrule is considerably stronger than itwould have been had the walls being merely vertically directed, Further,by assuring a flow of setting compound through apertures 31, 32, a stillstronger attach- 4 ment of brush handle to ferrule is achieved. Thehardening of the setting compound 16 serves to brace the thin side wallsof the shank and to rigidify the entire handle assembly, first byproviding a solid base portion, and second, by sealing the hollow handleagainst escape of air entrapped therein.

it will be readily recognized that the rigidifying action aforesaid willpermit great economies by allowing the use of relatively thin walled,relatively light weight handle assemblies as compared to the thicknessof walls which will be required if the rigidifying and sealing action ofthe setting compound were not present. It will thus be seen that thesetting compound as used with the novel brush assembly and handlesub-assembly herein described and claimed serves at least threefunctions, namely, to adhere the handle to the ferrule; to rigidify thehollow, thin-walled handle assembly; and to seal the hollow handleportion, thereby rigidifying the latter.

The brush assembly herein described and claimed will be readilyrecognized as having many advantages as compared with brush structuresheretofore known. By eliminating the nailing required in the prior brushstructures, the splitting in the bristle setting compound and in thehandle are eliminated without any sacrifice, and in fact, withaugmentation of the strength of bond between the handle and ferrule.Moreover, the assembly of handle to ferrule is greatly simplified, thusresulting in more economical production than in previously known brushstructures. Still further, the use of a bristle setting compound torigidity the handle structure, as previously described, permits the useof relatively thin-walled plastic handles, thus resulting in stillfurther economies, as well as providing non-fatiguing, light weightbrush assemblies.

Having thus described my invention and illustrated its use, what I claimas new and desire to secure by Letters Patent is:

l. In a method of producing a light weight rigid paint brush from ahandle segment having a deformable plastic handle including a hollow,thin-walled ferrule terminating in an open-mouthed shank and abristle-supporting tubular ferrule, the handle forming an extendedchamber in unobstructed communication with the shank which includesinserting into one end of the ferrule the butt ends of the bristles,cementing the butt ends of the same and exposing an overlying surpluslayer of cement at the opposite end of the ferrule and bristle assembly,the combination therewith of the steps of introducing the shank of thehandle with a tight fit into the open end of the ferrule to dip theshank into the cement in said overlying layer and to cause the cement tosurround the outer and inner walls of the shank so dipped into thecement, and then setting the cement to its rigid stage about the outerand inner walls of said shank, whereby to anchor the shank to theferrule and to brace and rigidity the walls of the shank of the handlein the cement.

2. A method of producing a paint brush having a hollow deformableplastic handle member having thin walls terminating in an open mouthportion comprising the steps of providing a tubular ferrule, filling oneend of said ferrule with the butt ends of bristles, introducingliquefied bristle setting compound into said ferrule, in contact withsaid butt ends of said bristles, introducing said open mouth portion ofsaid handle member into said ferrule with a friction fit to a pointbeneath the surface of said setting compound, flexing portions of saidhollow handle to redistribute said bristle setting compound with- 1nsaid ferrule and to extend about the inner and outer walls adjacent themouth portion, and causing said compound to harden.

3. A method of producing a paint brush having a hollow deformableplastic handle member having thin walls termmating in a downwardlydirected constricted open mouth portion and at least one transverseaperture in the walls formed in said handle adjacent said mouth portion,comprising the steps of providing a tubular ferrule,

sarars1 filling one end of said ferrule with the butt ends of bristles,introducing liquefied bristle setting compound into said ferrule incontact with said butt ends of said bristles, with an overlying excesslayer, introducing said mouth portion into said ferrule with a frictionfit and to submerge said aperture of said Walls defining said mouthportion to a point beneath the surface of said setting compound of saidoverlying layer, causing the portions of said handle defining saidaperture to be shifted by deforming said handle, and hardening saidbristle setting compound.

4. A brush comprising a tubular ferrule, a plurality of bristle membershaving their butt ends filling one end of said ferrule, a hollow,thin-walled integral handle member of relatively deformable plasticsecured in the other end of said ferrule and comprising an extended,open chamber through said handle member, said handle having at its lowerend a tapering shank having a passage to the interior of said handlesleeved in said ferrule, in proximate spaced relation to said butt endsof said bristles, and a mass ol hardened bristle setting compoundcontacting said butt ends and filling sai-d ferrule to a point abovesaid passage, whereby cementitiously to unite said bristles, ferrule andhandle as the sole means of union between said bristles, ferrule andhandle.

5. A brush in accordance with claim 4 wherein said handle includestapering walls defining a Shank projecting into said ferrule anddefining a mouth portion, said walls adjacent said other end of saidferrule, in the inserted position of said handle, providing a frictionalfit with the inner periphery of said other end of said ferrule and saidbristle setting compound being positioned in sealing relation in saidmouth portion.

6. A brush in accordance with claim 5 wherein said walls adjacent saidmouth portion are provided with a plurality of transverse aperturescommunicating with the chamber formed in said handle and said wallsadjacent said other end of said ferrule are oversize with respect to theinner periphery of said other end of said ferrule, whereby said wallshaving said apertures are shifted toward each other when said handle isinserted into said ferrule.

7. A paint brush construction comprising a tubular ferrule, a pluralityof bristle members having their butt ends projecting into one end ofsaid ferrule to ll said one end, a handle member having a hollow shankextending therefrom secured in the other end of said ferrule, saidhandle being thin walled and consisting of deformable plastic materialand including walls in said shank portion defining a downwardly directedopen mouth vportion, said walls adjacent said mouth portion having atleast one aperture communicating with the interior of said handle, cammeans on at least one said Wall in spaced relation to said aperture,whereby said wall having said cam means will be shifted laterally by thecamming engagement of said cam means with said other end of said ferrulewhen said handle is inserted in said ferrule, and

a mass of bristle setting compound partially filling said errule to apoint above said aperture.

8. A paint brush comprising a tubular ferrule, a plurality of bristlemembers having their butt ends projecting into one end of said ferruleto lill said one` end, a hollow, thin-Walled integral handle memberdefining an open chamber having a shank secured in the other end of saidferrule in communication with said chamber, said handle membercomprising relatively flexible plastic and including an integraloutwardly extending circumferential bead contacting said other end ofsaid ferrule and a plurality of integral skirt portions extending belowsaid bead, said skirt portions being angularly oriented with respect tothe major axis of said handle, with the portions of said skirts adjacentsaid bead being oversize with respect to the inner periphery of said-other end of said ferrule to frictionally tit thereinto, and a mass ofhardened bristle setting compound in Contact with said butt ends of saidbristle members and partially filling said ferrule to a point above thelowermost ends of said skirts.

9. A brush in accordance with claim 8 wherein said skirts definetransverse apertures positioned beneath the surface of said bristlesetting compound.

10. A plastic brush handle arranged to be connected with a brush bristlesection comprising a ferrule sleeve, in one end of which said bristlesare arranged to be cemented, said handle being integrally formed,thinwalled, and detining throughout its length a hollow chamber andterminating in a ferrule insertible shank segment having an open mouthin communication with said chamber arranged to be sleeved in said erruleendv/ise of said bristles with a tight iit to frictionally fit withinsaid ferrule and having a skirt and anchor portion extendible into thecement portion of said ferrule to anchor said skirt and anchor portionin said cemented portion to one side of said bristles and to have theskirt portion of said handle lilled and rigidified by the cemententering said shank segment on its outer and inner walls, thereby torigidify said shank and handle and cementitiously join said bristles,ferrule and handle.

References Cited by the Examiner UNITED STATES PATENTS 2,508,931 5/50Simms 15-171 2,562,716 7/51 Hervey 15-193 X 2,709,272 5/55 Pettengill15-171 2,913,751 11/59 Hardman et al. 15-143 X FOREIGN PATENTS 498,99911/ 54 Italy.

543,646 12/55 Belgium.

156,999 11/ 5 6 Sweden. 1,185,047 2/59 France.

CHARLES A. WILLMUTH, Primary Examiner.

1. IN A METHOD OF PRODUCING A LIGHT WEIGHT RIGID PAINT BRUSH FROM AHANDLE SEGMENT HAVING A DEFORMABLE PLASTIC HANDLE INCLUDING A HOLLOW,THIN-WALLED FERRULE TERMINATING IN AN OPEN-MOUTHED SHANK AND ABRISTLE-SUPPORTING TUBULAR FERRULE, THE HANDLE FORMING AN EXTENDEDCHAMBER IN UNOBSTRUCTED COMMUNICATION WITH THE SHANK WHICH INCLUDESINSERTING INTO ONE END OF THE FERRULE THE BUTT ENDS OF THE BRISTLES,CEMENTING THE BUTT ENDS OF THE SAME AND EXPOSING AN OVERLYING SURPLUSLAYER OF CEMENT AT THE OPPOSITE END OF THE FERRULE AND BRISTLE ASSEMBLY,THE COMBINATION THEREWITH OF THE STEPS OF INTRODUCING THE SHANK OF THEHANDLE WITH A TIGHT FIT INTO THE OPEN END OF THE FERRULE TO DIP THESHANK INTO THE CEMENT IN SAID OVERLYING LAYER AND TO CAUSE THE CEMENT TOSURROUND THE OUTER AND INNER WALLS OF THE SHANK SO DIPPED INTO THECEMENT, AND THEN SETTING THE CEMENT TO ITS RIGID STAGE ABOUT THE OUTERAND INNER WALLS OF SAID SHANK, WHEREBY TO ANCHOR THE SHANK TO THEFERRULE AND TO BRACE AND RIGIDIFY THE WALLS OF THE SHANK OF THE HANDLEIN THE CEMENT.
 4. A BRUSH COMPRISING A TUBULAR FERRULE, A PLURALITY OFBRISTLE MEMBERS HAVING THEIR BUTT ENDS FILLING ONE END OF SAID FERRULE,A HOLLOW, THIN-WALLED INTEGRAL HANDLE MEMBER OF RELATIVELY DEFORMABLEPLASTIC SECURED IN THE OTHER END OF SAID FERRULE AND COMPRISING ANEXTENDED, OPEN CHAMBER THROUGH SAID HANDLE MEMBER, SAID HANDLE HAVING ATITS LOWER END A TAPERING SHANK HAVING A PASSAGE TO THE INTERIOR OF SAIDHANDLE SLEEVED IN SAID FERRULE. APPROXIMATE SPACED RELATION TO SAID BUTTENDS OF SAID BRISTLES, AND A MASS OF HARDENED BRISTLE SETTING COMPOUNDCONTACTING SAID BUTT ENDS AND FILLING SAID FERRULE TO A POINT ABOVE SAIDPASSAGE, WHEREBY CEMENTITIOUSLY TO UNITE SAID BRISTLES, FERRULE ANDHANDLE AS THE SOLE MEANS OF UNION BETWEEN SAID BRISTLES, FERRULE ANDHANDLE.